Course Outline
Module 1 – Introduction to Quality Core Tools
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Evolution of AIAG Quality Core Tools
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Relationship between APQP, PPAP, FMEA, SPC and MSA
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Core Tools throughout the product lifecycle
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Integration with IATF 16949 quality requirements
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Role of Core Tools within project and quality management
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Common implementation challenges and best practices
Module 2 – Advanced Product Quality Planning (APQP)
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APQP objectives and benefits
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The five phases of APQP
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Cross-functional project planning
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Customer requirements and Voice of the Customer
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Risk-based planning
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Deliverables within each APQP phase
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Managing project milestones
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APQP documentation
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Practical APQP case study
Module 3 – Production Part Approval Process (PPAP)
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Purpose of PPAP
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AIAG PPAP requirements
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PPAP submission levels
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Required documentation package
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Customer approval process
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Initial Sample Inspection
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Process validation
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Typical customer expectations
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Common PPAP mistakes
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Practical PPAP documentation workshop
Module 4 – Process Failure Mode and Effects Analysis (PFMEA)
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AIAG-VDA FMEA methodology
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Seven-step FMEA approach
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Structure analysis
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Function analysis
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Failure analysis
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Risk analysis
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Action prioritization
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Optimization and continual improvement
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Maintaining living FMEA documents
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Practical PFMEA workshop
Module 5 – Control Plan Integration
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Purpose of the Control Plan
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Relationship between PFMEA and Control Plans
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Characteristics and control methods
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Reaction plans
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Maintaining Control Plans
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Practical Control Plan exercise
Module 6 – Practical SPC Refresher
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Review of Statistical Process Control concepts
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Control charts overview
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Process stability
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Process capability (Cp, Cpk)
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Interpretation of SPC data
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Common SPC pitfalls
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Practical interpretation exercises
Module 7 – Practical MSA Refresher
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Review of Measurement Systems Analysis
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Accuracy, precision and bias
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Gauge Repeatability and Reproducibility (GR&R)
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Attribute agreement analysis
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Interpretation of MSA studies
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Common measurement system issues
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Practical examples
Module 8 – Integrating the Core Tools
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Using Core Tools throughout product realization
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Information flow between APQP, PFMEA, Control Plans and PPAP
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Linking SPC and MSA to process validation
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Practical end-to-end automotive project case study
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Preparing for successful application in daily work
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Knowledge review and discussion
Requirements
Participants should have:
- A solid understanding of manufacturing quality management principles
- Familiarity with the product development and production lifecycle
- Experience in quality assurance, quality engineering, project engineering, or manufacturing processes
- Prior exposure to APQP, PPAP, FMEA, SPC, and MSA through internal training or practical work
- No programming experience is necessary
What delegates should know prior to the course?
- Basic knowledge of the AIAG Quality Core Tools
- Work experience in Quality, Manufacturing, or Project Engineering within an industrial setting
- Familiarity with IATF 16949 or automotive quality processes is advantageous but not mandatory
- Practical experience in product or process development projects is recommended
Audience
This course is intended for:
- Quality Engineers
- Project Engineers
- Supplier Quality Engineers
- Manufacturing Engineers
- Process Engineers
- Quality Specialists
- Continuous Improvement Engineers
- New Product Introduction (NPI) Engineers
- Professionals preparing for VDA 6.3 Process Auditor training
